Luminaire Utilizing Waveguide

ABSTRACT

A luminaire includes a housing, an optical waveguide disposed in the housing comprising a plurality of light coupling cavities, and a plurality of LEDs disposed in the housing adjacent the plurality of coupling cavities. A mounting apparatus is adapted to mount the luminaire on a roadway stanchion.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional PatentApplication No. 61/922,017, filed Dec. 30, 2013, entitled “OpticalWaveguide Bodies and Luminaires Utilizing Same” (Cree docket No.P2143US0), U.S. Provisional Patent Application No. 62/005,955, filed May30, 2014, entitled “Parking Structure LED Light” (Cree docket No.P2238US0), U.S. Provisional Patent Application No. 62/009,039, filedJun. 6, 2014, entitled “Parking Structure LED Light” (Cree docket No.P2238US0-2), U.S. Provisional Patent Application No. 62/005,965, filedMay 30, 2014, entitled “Luminaire Utilizing Waveguide” (Cree docket No.P2237US0), U.S. Provisional Patent Application No. 62/025,436, filedJul. 16, 2014, entitled “Luminaire Utilizing Waveguide” (Cree docket No.P2237US0-2), and U.S. Provisional Patent Application No. 62/025,905,filed Jul. 17, 2014, entitled “Luminaire Utilizing Waveguide” (Creedocket No. P2237US0-3), all owned by the assignee of the presentapplication and the disclosures of which are incorporated by referenceherein. The present application further comprises a continuation-in-partof U.S. patent application Ser. No. 13/842,521, filed Mar. 15, 2013,entitled “Optical Waveguides” (Cree docket No. P1946US1), and furthercomprises a continuation-in-part of U.S. patent application Ser. No.13/839,949, filed Mar. 15, 2013, entitled “Optical Waveguide and LampIncluding Same” (Cree docket No. P1961US1), and further comprises acontinuation-in-part of U.S. patent application Ser. No. 13/841,074,filed Mar. 15, 2013, entitled “Optical Waveguide Body” (Cree docket No.P1968US1), and further comprises a continuation-in-part of U.S. patentapplication Ser. No. 13/840,563, filed Mar. 15, 2013, entitled “OpticalWaveguide and Luminaire Incorporating Same” (Cree docket No. P2025US1),and further comprises a continuation-in-part of U.S. application Ser.No. 13/841,622, filed Mar. 15, 2013, entitled “Shaped Optical WaveguideBodies” (Cree docket No. P2020US1), and further comprises acontinuation-in-part of U.S. patent application Ser. No. 13/938,877,filed Jul. 10, 2013, entitled “Optical Waveguide and LuminaireIncorporating Same” (Cree docket No. P2025US2), and further comprises acontinuation-in-part of U.S. patent application Ser. No. 14/015,801,filed Aug. 30, 2013, entitled “Consolidated Troffer” (Cree docket No.P1883US1), and further comprises a continuation-in-part of U.S. patentapplication Ser. No. 14/101,086, filed Dec. 9, 2013, entitled “OpticalWaveguides and Luminaires Incorporating Same” (Cree docket No.P2126US1), and further comprises a continuation-in-part of U.S. patentapplication Ser. No. 14/101,147, filed Dec. 9, 2013, entitled“Luminaires Using Waveguide Bodies and Optical Elements” (Cree docketNo. P2131US1), and further comprises a continuation-in-part of U.S.patent application Ser. No. 14/101,099, filed Dec. 9, 2013, entitled“Optical Waveguide Assembly and Light Engine Including Same” (Creedocket No. P2129US1), and further comprises a continuation-in-part ofU.S. patent application Ser. No. 14/101,129, filed Dec. 9, 2013,entitled “Simplified Low Profile Module With Light Guide For Pendant,Surface Mount, Wall Mount and Stand Alone Luminaires” (Cree docket No.P2141US1), and further comprises a continuation-in-part of U.S. patentapplication Ser. No. 14/101,051, filed Dec. 9, 2013, entitled “OpticalWaveguide and Lamp Including Same” (Cree docket No. P2151US1), andfurther comprises a continuation-in-part of International ApplicationNo. PCT/US14/13937, filed Jan. 30, 2014, entitled “Optical WaveguideBodies and Luminaires Utilizing Same” (Cree docket No. P2143WO), andfurther comprises a continuation-in-part of International ApplicationNo. PCT/US14/13931, filed Jan. 30, 2014, entitled “Optical Waveguidesand Luminaires Incorporating Same” (Cree docket No. P2126WO), andfurther comprises a continuation-in-part of International ApplicationNo. PCT/US14/30017, filed Mar. 15, 2014, entitled “Optical WaveguideBody” (Cree docket No. P2225WO), and further comprises acontinuation-in-part of U.S. patent application Ser. No. 14/462,426,filed Aug. 18, 2014, entitled “Outdoor and/or Enclosed Structure LEDLuminaire for General Illumination Applications, Such as Parking Lotsand Structures” (Cree docket No. P2238US1), and further comprises acontinuation-in-part of U.S. patent application Ser. No. 14/462,391,filed Aug. 18, 2014, entitled “Optical Components for Luminaire” (Creedocket No. P2266US1), all owned by the assignee of the presentapplication and the disclosures of which are incorporated by referenceherein.

REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

SEQUENTIAL LISTING

Not applicable

FIELD OF THE INVENTION

The present subject matter relates to optical devices, and moreparticularly, to a luminaire utilizing an optical waveguide.

BACKGROUND OF THE INVENTION

An optical waveguide mixes and directs light emitted by one or morelight sources, such as one or more light emitting diodes (LEDs). Atypical optical waveguide includes three main components: one or morecoupling elements, one or more distribution elements, and one or moreextraction elements. The coupling component(s) direct light into thedistribution element(s), and condition the light to interact with thesubsequent components. The one or more distribution elements control howlight flows through the waveguide and is dependent on the waveguidegeometry and material. The extraction element(s) determine how light isremoved by controlling where and in what direction the light exits thewaveguide.

When designing a coupling optic, the primary considerations are:maximizing the efficiency of light transfer from the source into thewaveguide; controlling the location of light injected into thewaveguide; and controlling the angular distribution of the light in thecoupling optic. One way of controlling the spatial and angular spread ofinjected light is by fitting each source with a dedicated lens. Theselenses can be disposed with an air gap between the lens and the couplingoptic, or may be manufactured from the same piece of material thatdefines the waveguide's distribution element(s). Discrete couplingoptics allow numerous advantages such as higher efficiency coupling,controlled overlap of light flux from the sources, and angular controlof how the injected light interacts with the remaining elements of thewaveguide. Discrete coupling optics use refraction, total internalreflection, and surface or volume scattering to control the distributionof light injected into the waveguide.

After light has been coupled into the waveguide, it must be guided andconditioned to the locations of extraction. The simplest example is afiber-optic cable, which is designed to transport light from one end ofthe cable to another with minimal loss in between. To achieve this,fiber optic cables are only gradually curved and sharp bends in thewaveguide are avoided. In accordance with well-known principles of totalinternal reflectance light traveling through a waveguide is reflectedback into the waveguide from an outer surface thereof, provided that theincident light does not exceed a critical angle with respect to thesurface.

In order for an extraction element to remove light from the waveguide,the light must first contact the feature comprising the element. Byappropriately shaping the waveguide surfaces, one can control the flowof light across the extraction feature(s). Specifically, selecting thespacing, shape, and other characteristic(s) of the extraction featuresaffects the appearance of the waveguide, its resulting distribution, andefficiency.

Hulse U.S. Pat. No. 5,812,714 discloses a waveguide bend elementconfigured to change a direction of travel of light from a firstdirection to a second direction. The waveguide bend element includes acollector element that collects light emitted from a light source anddirects the light into an input face of the waveguide bend element.Light entering the bend element is reflected internally along an outersurface and exits the element at an output face. The outer surfacecomprises beveled angular surfaces or a curved surface oriented suchthat most of the light entering the bend element is internally reflecteduntil the light reaches the output face

Parker et al. U.S. Pat. No. 5,613,751 discloses a light emitting panelassembly that comprises a transparent light emitting panel having alight input surface, a light transition area, and one or more lightsources. Light sources are preferably embedded or bonded in the lighttransition area to eliminate any air gaps, thus reducing light loss andmaximizing the emitted light. The light transition area may includereflective and/or refractive surfaces around and behind each lightsource to reflect and/or refract and focus the light more efficientlythrough the light transition area into the light input surface of thelight-emitting panel. A pattern of light extracting deformities, or anychange in the shape or geometry of the panel surface, and/or coatingthat causes a portion of the light to be emitted, may be provided on oneor both sides of the panel members. A variable pattern of deformitiesmay break up the light rays such that the internal angle of reflectionof a portion of the light rays will be great enough to cause the lightrays either to be emitted out of the panel or reflected back through thepanel and emitted out of the other side.

Shipman, U.S. Pat. No. 3,532,871 discloses a combination running lightreflector having two light sources, each of which, when illuminated,develops light that is directed onto a polished surface of a projection.The light is reflected onto a cone-shaped reflector. The light istransversely reflected into a main body and impinges on prisms thatdirect the light out of the main body.

Simon U.S. Pat. No. 5,897,201 discloses various embodiments ofarchitectural lighting that is distributed from contained radiallycollimated light. A quasi-point source develops light that is collimatedin a radially outward direction and exit means of distribution opticsdirect the collimated light out of the optics.

Kelly et al. U.S. Pat. No. 8,430,548 discloses light fixtures that use avariety of light sources, such as an incandescent bulb, a fluorescenttube and multiple LEDs. A volumetric diffuser controls the spatialluminance uniformity and angular spread of light from the light fixture.The volumetric diffuser includes one or more regions of volumetric lightscattering particles. The volumetric diffuser may be used in conjunctionwith a waveguide to extract light.

Dau et al U.S. Pat. No. 8,506,112 discloses illumination devices havingmultiple light emitting elements, such as LEDs disposed in a row. Acollimating optical element receives light developed by the LEDs and alight guide directs the collimated light from the optical element to anoptical extractor, which extracts the light.

A.L.P. Lighting Components, Inc. of Niles, Ill., manufactures awaveguide having a wedge shape with a thick end, a narrow end, and twomain faces therebetween. Pyramid-shaped extraction features are formedon both main faces. The wedge waveguide is used as an exit sign suchthat the thick end of the sign is positioned adjacent a ceiling and thenarrow end extends downwardly. Light enters the waveguide at the thickend and is directed down and away from the waveguide by thepyramid-shaped extraction features.

Low-profile LED-based luminaires have recently been developed (e.g.,General Electric's ET series panel troffers) that utilize a string ofLED components directed into the edge of a waveguiding element (an“edge-lit” approach). However, such luminaires typically suffer from lowefficiency due to losses inherent in coupling light emitted from apredominantly Lambertian emitting source such as a LED component intothe narrow edge of a waveguide plane.

Smith U.S. Pat. Nos. 7,083,313 and 7,520,650 discloses a light directiondevice for use with LEDs. In one embodiment, the light direction deviceincludes a plurality of opposing collimators disposed about a pluralityof LEDs on one side of the device. Each collimator collimates lightdeveloped by the LEDs and directs the collimated light through outputsurfaces of the collimators toward angled reflectors disposed on asecond side opposite the first side of the device. The collimated lightreflects off the reflectors out of from the one side perpendicularthereto. In another embodiment, the collimators are integral with awaveguide having reflective surfaces disposed on a second side of thewaveguide, and the collimated light is directed toward the reflectivesurfaces. The light incident on the reflective surfaces is directed fromthe one side of the device, as in the one embodiment.

In some applications such as roadway, street, or parking lot lighting,it may be desirable to illuminate certain regions surrounding a lightfixture while maintaining relatively low illumination of neighboringregions thereof. For example, along a roadway, it may be preferred todirect light in a lateral direction parallel with the roadway whileminimizing illumination in a longitudinal direction toward roadsidehouses.

SUMMARY OF THE INVENTION

According to one aspect, A luminaire includes a housing, an opticalwaveguide disposed in the housing comprising a plurality of lightcoupling cavities, and a plurality of LEDs disposed in the housingadjacent the plurality of coupling cavities. A mounting apparatus isadapted to mount the luminaire on a roadway stanchion.

According to another aspect, an optical waveguide body of opticallytransmissive material that exhibits a total internal reflectancecharacteristic comprises an array of light coupling features and atleast one light redirection surface offset with respect to the array oflight coupling features and extending along a first direction. Theoptical waveguide body further includes at least one extraction surfaceextending along a second direction transverse to the first direction.

According to a further aspect, an optical waveguide body of opticallytransmissive material that exhibits a total internal reflectancecharacteristic includes a coupling portion for receiving light, atransmission portion for transmitting light through at least a portionof the body, and an extraction portion for extracting light out of thebody. The transmission portion includes light redirection featuresextending along a first direction and the extraction portion includesextraction features extending along a second direction transverse to thefirst direction.

According to another aspect, an optical assembly includes an opticalwaveguide, an enclosure having a recess that receives the opticalwaveguide, and a surround member formed about the housing and thewaveguide for securing the optical waveguide in the recess.

Other aspects and advantages of the present invention will becomeapparent upon consideration of the following detailed description andthe attached drawings wherein like numerals designate like structuresthroughout the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view from above of a luminaire;

FIG. 2 is an isometric view from below of the luminaire of FIG. 1;

FIG. 3 is a further isometric view from above of the luminaire of FIG.1;

FIG. 4 is an exploded isometric view of the luminaire of FIG. 1;

FIG. 5 is another exploded isometric view of the luminaire of FIG. 1;

FIG. 6 is a fragmentary isometric view from below of a mounting portionof the luminaire of FIG. 1;

FIG. 7 is a partial exploded fragmentary side isometric view of themounting portion of FIG. 6;

FIG. 8 is a partial exploded plan view of the mounting portion of FIG.6;

FIG. 9 is another partial exploded plan view of the mounting portion ofFIG. 6;

FIG. 10 is an isometric view of a waveguide body;

FIG. 10A is a fragmentary plan view of a light extraction feature incombination with an LED;

FIG. 11 is an isometric view of a bottom surface of the waveguide bodyof FIG. 10;

FIG. 11A is a plan view of the waveguide body of FIG. 10;

FIG. 12 is a graph of the illumination pattern of the waveguide body ofFIG. 10;

FIG. 13 is an isometric view of a heat pipe shown in FIG. 5;

FIG. 14 is an exploded view of the heat pipe of FIG. 13;

FIG. 15 is a further exploded view of the heat pipe of FIG. 13;

FIG. 16 is a partial exploded view of the luminaire of FIG. 1 frombelow;

FIG. 17 is an exploded isometric view of the luminaire of FIG. 1;

FIG. 18 is an exploded isometric view from below of another embodimentof a luminaire;

FIG. 19 is an exploded isometric view from above of the luminaire ofFIG. 18;

FIG. 20 is an isometric view of the waveguide body of FIG. 18;

FIG. 21 is a plan view of the waveguide body of FIG. 20;

FIG. 22 is a fragmentary, enlared plan view of coupling cavities of thewaveguide body of FIG. 20;

FIG. 23 is a bottom elevational view of the waveguide body of FIG. 20;

FIG. 24 is a side elevational view of the waveguide body of FIG. 20;

FIG. 25 is an isometric view of the waveguide body of FIG. 20;

FIG. 26 is a graph of the illumination pattern produced by the waveguidebody of FIG. 20;

FIG. 27 is an isometric view from below of an embodiment of a luminaire;

FIG. 28 is an isometric view from above of another embodiment of aluminaire;

FIG. 29 is an isometric view from below of the luminaire of FIG. 28;

FIG. 30 is an exploded isometric view of the luminaire of FIG. 27;

FIG. 31 is a fragmentary bottom perspective view of a portion of theluminaire of FIG. 28;

FIG. 32 is a fragmentary top perspective view of a portion of theluminaire of FIG. 28;

FIG. 33 is a fragmentary exploded isometric view of a portion of theembodiment of FIG. 30;

FIG. 34 is an isometric view from below of another embodiment of aluminaire;

FIG. 35 is an isometric view from above of the luminaire of FIG. 34;

FIG. 36 is a plan view of the luminaire of FIG. 34;

FIG. 37 is a side elevational view of the luminaire of FIG. 34;

FIG. 38 is an isometric view from above of the luminaire of FIG. 34 anda smaller version of the luminaire of FIG. 34;

FIG. 39 is an isometric view from below of the two luminaires of FIG.38;

FIG. 40 is a plan view of yet another embodiment of a luminaire;

FIGS. 41 and 42 are plan views of embodiments of FIG. 38;

FIGS. 43 and 43A are graphs illustrating light distributions produced byan embodiment of a luminaire disclosed herein;

FIGS. 44-50 are photographs of portions of the embodiment of FIG. 30;

FIGS. 51 and 52 are front and rear top isometric views, respectively, ofyet another embodiment;

FIG. 53 is a bottom front isometric view of the embodiment of FIGS. 51and 52;

FIGS. 54 and 55 are front and rear top isometric views respectively, ofa further embodiment similar to but larger than the embodiment of FIGS.51-53;

FIG. 56 is an exploded isometric view of the embodiment of FIGS. 51-53;

FIG. 57 is an exploded isometric view illustrating the optic assembly,power supply, LED board, and heat sink of FIG. 56;

FIG. 58 is a bottom isometric view of the embodiment of FIGS. 51-53 witha bottom door removed and illustrating installation of a terminal blockand clasp;

FIG. 59 is a bottom isometric view of the embodiment of FIGS. 51-53illustrating installation of the bottom door;

FIG. 60 is a sectional view taken generally along the lines 60-60 ofFIG. 59 illustrating the door after installation thereof;

FIGS. 61-63 are isometric views illustrating optical waveguide bodiesthat may be used in the embodiments of FIGS. 51-55 to achieve differentillumination distributions wherein the waveguide bodies are identicalexcept for the shape of a central portion 600 and, possibly, the overallsizes of the waveguides depending upon whether the waveguide body isused in the embodiment of FIGS. 51-53 or the embodiment of FIGS. 54 and55;

FIGS. 64 and 65 are top and bottom isometric views, respectively, of theoptic assembly of FIG. 57;

FIGS. 66-68 are isometric views of one of the waveguide bodies (alsoreferred to as an optic) of FIGS. 61-63, a reflective enclosure member(or optic box) within which the waveguide body is disposed, and asurround member that surrounds the waveguide, respectively, of the opticassembly of FIGS. 64 and 65;

FIG. 69 is a bottom isometric view of another waveguide body that may beused in either the embodiment of FIGS. 51-53 or the embodiment of FIGS.54 and 55;

FIGS. 70-74 are top isometric, plan, front elevational, sideelevational, and rear elevational views, respectively, of the waveguidebody of FIG. 69;

FIGS. 75, 75A, 75B, and 75C are a sectional elevational line view, asectional elevational shaded view, a sectional isometric line view, anda sectional isometric shaded view, respectively, all taken along thelines 75-75 of FIG. 69;

FIGS. 76, 76A, 76B, and 76C are a sectional elevational line view, asectional elevational shaded view, a sectional isometric line view, anda sectional isometric shaded view, respectively, all taken along thelines 76-76 of FIG. 69;

FIGS. 77, 77A, 77B, and 77C are a sectional elevational line view, asectional elevational shaded view, a sectional isometric line view, anda sectional isometric shaded view, respectively, all taken along thelines 77-77 of FIG. 69;

FIGS. 78 and 79 are perspective views of embodiments of FIGS. 51-55 withvarious details specified therein;

FIG. 80 is an isometric view of the optic assembly of FIG. 57;

FIG. 81 is a top isometric view of a further embodiment;

FIG. 82 is an exploded isometric view of the embodiment of FIG. 81;

FIG. 83 is a bottom isometric view of the embodiment of FIG. 81;

FIG. 84 is a plan view of the embodiment of FIG. 81;

FIG. 85 is a front elevational view of the embodiment of FIG. 81;

FIG. 86 is a rear elevational view of the embodiment of FIG. 81;

FIG. 87 is a sectional elevational view taken generally along the lines87-87 of FIG. 81;

FIG. 88 is an isometric view of an optic assembly that may be used inthe embodiment of FIG. 81;

FIG. 89 is an exploded isometric view of the optic assembly of FIG. 88;

FIG. 90 is an isometric view of an alternative embodiment of a waveguidebody that may be used in the embodiment of FIG. 81;

FIGS. 90A and 90B are fragmentary, enlarged plan views of a plurality ofcoupling cavities that may be used in the embodiment of FIG. 81;

FIG. 91 is an isometric view of a further embodiment of a waveguide bodythat may be used in the embodiment of FIG. 81;

FIG. 92 is a top isometric view of a further embodiment;

FIG. 93 is a bottom isometric view of a portion of the embodiment ofFIG. 92 with a bottom cover removed to reveal inner portions of theluminaire;

FIG. 94 is an isometric view of an optic assembly that may be used inthe embodiment of FIG. 92;

FIG. 95 is an exploded isometric view of the optic assembly of FIG. 99;

FIG. 96 is a bottom isometric view of a waveguide body that may be usedin the embodiment of FIG. 92;

FIGS. 97-99 are top isometric views of alternative waveguide bodies thatmay be used in the embodiment of FIG. 92;

FIG. 97A is a plan view of an alternative embodiment waveguide body;

FIGS. 97B and 97C are sectional elevational views taken generally alongthe lines 97B-97B and lines 97C-97C, respectively, of FIG. 97A; and

FIG. 100 is a ray trace diagram of a waveguide body having a side wallfeature common to the waveguide bodies of FIGS. 97-99.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1-17, a luminaire 10 that utilizes a waveguide isillustrated. The luminaire 10, as well as other embodiments disclosedherein, are particularly adapted for use in general lightingapplications, for example, as an outdoor roadway (including a driveway)or parking lot luminaire, or as any other indoor or outdoor luminaire.The luminaire 10 includes a housing 12 adapted to be mounted on astanchion or pole 14 (see FIG. 16). More particularly, the housing 12includes a mounting portion 16 that is sized to accept an end of any ofa number of conventional stanchions. A set screw (not shown) is threadedthrough a bore 17 (see FIGS. 2 and 3) and against an end of thestanchion 14 (see FIG. 16) to secure the luminaire 10 in fixed positionon the end of the stanchion 14. The housing 12 may be secured to thestanchion 14 by any suitable means. Referring to FIG. 6, electricalconnections (i.e., line, ground, and neutral) are effectuated via aterminal block 18 disposed within a fitter compartment 20 of themounting portion 16. The fitter compartment 20 is accessible via amovable fitter door 21 (see FIG. 5), which is rotatable about a pivotedhinge 22 and which can be maintained in a closed position by a latch(not shown). Wires (not shown) connect the terminal block 18 to an LEDdriver circuit in the housing 12 to provide power thereto as noted ingreater detail hereinafter.

A head portion 24 of the housing 12 is movable relative to the mountingportion 16 by an adjustment apparatus 26 as shown in FIGS. 7-9 and 21.More particularly, a base member 27 of a mounting bracket 28 is fixedlymounted by any suitable means in an end recess 29 (see FIG. 4) of thehead portion 24. The mounting bracket 28 further includes a bearingplate 31 transverse to the base member 27, and first, second, and thirdtabs 32 a, 32 b, and 32 c transverse to the bearing plate 31. As seen inFIGS. 7-9, a curved surface 34 carried by the mounting portion 16includes a slot 36 that receives the bearing plate 31 such that thecurved surface 34 is captured between the tabs 32 a, 32 b to guide themounting bracket 28, and hence, the head portion 24, through a curvedrange of motion. A set screw 35 is threaded into a bore 35 a in themounting portion 16 and bears against the bearing plate 31 to maintainthe position of the head portion 24 relative to the mounting portion 16at a desired position. The tab 32 c limits travel of the head portion 24upwardly relative to the mounting portion 16 through interferencethereof with a bottom surface 36 a adjacent the curved surface 34.

Referring next to FIGS. 4 and 5, the head portion 24 comprises a covermember 37, an optional heat pipe 38, a reflective enclosure member 39,and an optical waveguide comprising a waveguide body or optic 40. Agasket 41 surrounds an outer edge of the waveguide body 40 and thevarious components are sandwiched between the waveguide body 40 and thecover member 37 by deflecting tabs 37 a of the cover member 37 upwardlyand inwardly against the assembled elements. A sensor 23 may be disposedatop the mounting portion 16 for sensing ambient light conditions orother parameters and a signal representative thereof may be provided tothe LED driver circuit in the housing 12.

Referring next to FIGS. 10-12, an embodiment of a waveguide body 340includes a top surface 342, a bottom surface 343 forming a part of asubstrate 343 a, and at least one, and, more preferably, a plurality oflight coupling cavities 344 a-344 e extending into the waveguide body340 from an end surface 345. A number of light redirection elements 346define the top surface 342 and are disposed atop the substrate 343 a. Anoptional plurality of light extraction features 367 may be disposed onthe bottom surface 343. LED elements (see FIG. 10A) 348 comprising lightsources are disposed in or adjacent each of the plurality of lightcoupling cavities 344 as described in greater detail below.

As seen in FIG. 10, the plurality of light coupling cavities 344 are allpreferably of substantially the same shape, although different shapesmay be used to effectuate a desired illumination pattern. As seen inFIG. 10A, each light coupling cavity 344 is defined by a surface 356that is substantially or generally hemispherical in cross section andthe cavity 344 is preferably cylindrical in the sense that the generalhemispherical shape is unchanged along a length of the cavity 344. Thesurface 356 defining each light coupling cavity 344 may be smooth,textured, curved, or otherwise shaped to affect light mixing and/orredirection. For example, as seen in FIG. 10A, the surface 356 includesan arrangement of protrusions 380 separated from one another byintervening grooves 382 to promote light mixing. Such an arrangement maytake any of the forms disclosed in International Application No.PCT/US14/30017, filed Mar. 15, 2014, entitled “Optical Waveguide Body”(Cree docket No. P2225WO), incorporated by reference herein. Thearrangement promotes color mixing in the event that different color LEDs348 are used and/or promote illuminance uniformity by the waveguide body340 regardless of whether multi-color or monochromatic LEDs are used.

In any of the embodiments disclosed herein other light mixing featuresmay be included in or on the waveguide body 340, for example, one ormore bodies of differing index or indices of refraction than remainingportions of the waveguide body 340 may extend into the waveguide bodyand/or be located fully within the waveguide body 40.

As described in greater detail hereinafter in connection with FIG. 11A,LED elements 348 are disposed within or adjacent the coupling cavities344 a-344 e of the waveguide body 340. Each LED element 348 may be asingle white or other color LED, or each may comprise multiple LEDseither mounted separately or together on a single substrate or packageto form a module including, for example, at least one phosphor-coated orphosphor-converted LED, such as a blue-shifted yellow LED, either aloneor in combination with at least one color LED, such as a green LED, ayellow LED, a red LED, etc. The number and configuration of LEDs 48 mayvary depending on the shape(s) of the coupling cavity.

Different color temperatures and appearances could be produced usingparticular LED combinations, as is known in the art. In one embodiment,each light source comprises any LED, for example, an MT-G LEDincorporating TrueWhite® LED technology or as disclosed in U.S. patentapplication Ser. No. 13/649,067, filed Oct. 10, 2012, entitled “LEDPackage with Multiple Element Light Source and Encapsulant Having PlanarSurfaces” by Lowes et al., (Cree Docket No. P1912US1-7), the disclosureof which is hereby incorporated by reference herein, as developed andmanufactured by Cree, Inc., the assignee of the present application. Inanother embodiment, a plurality of LEDs may include at least two LEDshaving different spectral emission characteristics. If desirable, one ormore side emitting LEDs disclosed in U.S. Pat. No. 8,541,795, thedisclosure of which is incorporated by reference herein, may be utilizedinside or at the edge of the waveguide body 40, 340 (the option to useLEDs inside the waveguide body is discussed below). In any of theembodiments disclosed herein the LED elements 48 preferably have aLambertian light distribution, although each may have a directionalemission distribution (e.g., a side emitting distribution), as necessaryor desirable. More generally, any Lambertian, symmetric, wide angle,preferential-sided, or asymmetric beam pattern LED(s) may be used as thelight source.

Referring to FIGS. 10 and 11, the light redirection elements 346 includeat least a plurality of light extraction features 363 a-363 e. The lightextraction features 363 a-363 e are linear in overall side-to-sideextent or shape and include five wedge-shaped (in cross-section)extraction features. Further, the light extraction features 363 a-363 eare preferably symmetric with respect to a centerline 365 of thewaveguide body 340, although other configurations are envisioned. Inother embodiments, the width, length, and curvature and/or othershape(s) of the extraction features may vary.

The substrate 343 a may be integral with the redirection elements 346 orthe redirection elements 346 may be separately formed and placed on orotherwise disposed and retained relative to the substrate 343 a, asdesired. The substrate 343 a and some or all of the redirection elementsmay be made of the same or different materials.

The waveguide body 340 is made of suitable optical materials, such asone or more of acrylic, air, polycarbonate, molded silicone, glass,cyclic olefin copolymers, and/or a liquid, including water and/ormineral oils, and combinations thereof, possibly in a layeredarrangement, to achieve a desired effect and/or appearance.

The light developed by the LEDs 348 travels through the waveguide body340 and is redirected downwardly by the extraction features 363 and isemitted out the bottom or emission surface 343 of the waveguide body340. The optional light extraction features 367, which may comprise twosets of parallel features extending transverse to the extent of thefeatures 363, further facilitate light extraction. It should be notedthat the light extraction features 347 may not be needed in the casewhere the light extraction features 363 are optically decoupled from thesubstrate 343 a, resulting in an air gap between the features 363 andthe substrate 343 a preventing substantial retention of light in thesubstrate 343 a. Such an optically decoupled condition may exist, forexample, where the extraction features 363 are not intimately opticallybonded to the substrate 343 a, but are non-intimately retained thereon,such as by one or more mechanical elements.

The waveguide body 340 directs light developed by the LED element(s) 348toward a desired illumination target surface, such as a roadway, with anillumination pattern 350, for example, as seen in FIG. 12. Theillumination pattern 350 is preferably, although not necessarily, offsetwith respect to a center of the waveguide body as described above.Referring to FIG. 12, the extraction features 363 are configured todevelop an asymmetric light distribution having a lateral first maximumextent offset from the lateral axis 359 (see FIG. 10). The lightdistribution further has a longitudinal second maximum extent alignedwith the longitudinal axis 365. The lateral first maximum extent islarger than the longitudinal second maximum extent. Specifically, theluminaire is located at the center (0, 0) of the graph of FIG. 12 andhas a mounting height of 20 feet. Further, the illumination area isdisposed away from the center 359 in the direction of the arrow 365 a,with the magnitude of the offset and the size and, possibly, the shapesof the illumination area being a function of distance of the luminairefrom the target surface, as should be evident. An alternative lightdistribution 856 is illustrated in FIGS. 43 and 43A.

Further, the LED elements 348 may be disposed in some other arrangementrelative to one another and relative to the light coupling cavities. TheLED elements 348 may be mounted on individual support structures ormultiple elements may be mounted on a single support structure. In theillustrated embodiment, the LEDs 348 are disposed on and carried by ametal coated printed circuit board (PCB) 66 (FIG. 4) that is, in turn,held in place relative to an opening 68 of the reflective enclosuremember 39 by a holder assembly 70. The holder assembly 70 comprises amain holding member 72 and a flexible compression strip 73. The mainholding member 72 is held in place on the reflective enclosure member 39by a first set of hooked members 74 and a second pair of hooked members75 of the reflective enclosure member 39 that bear against a pair ofupstanding posts 76 and a ledge 77, respectively, of the main holdingmember 72. A set of upstanding teeth 78 bear against a central portion79 of the heat pipe 38 and the compression strip 73 is firmly capturedbetween the central portion 79 and a back surface of the PCB 66. A frontsurface of the PCB 73 on which the LEDs are disposed is disposedadjacent a vertical surface 80 of the main holding member 72 such thateach LED 48 extends into an associated one of a plurality of rectangularor square openings 81 a-81 e. The flexible or rigid PCB 73 is sandwichedbetween compression strip 72 and heat pipe 79. A force is exerted by theupstanding teeth 78 toward the heat pipe 79. The compression forceexerted by the upstanding teeth 78 maintains a thermal conduction pathbetween the heat pipe 79 and the PCB 73. The waveguide body 40 (FIG.16), 340 (FIG. 10) is disposed and maintained within an inside surfaceof the reflective enclosure member 39 such that the coupling cavities344 a-344 e are disposed in a fixed relationship adjacent the openings81 a-81 e, respectively, and the LEDs 48, 348. Each LED receives powerfrom an LED driver circuit or power supply of suitable type, such as aSEPIC-type power converter and/or other power conversion circuitscarried by a circuit board 81 that is mounted by fasteners 82 andlocating pins 83 (FIG. 4) atop the reflective enclosure member 39.

Side portions 83 a, 83 b of the heat pipe 38 are disposed and heldwithin four support brackets 84 a-84 d carried by the reflectiveenclosure member 39. The portions 83 a, 83 b are thus disposed adjacentan inside surface of the cover member 37, and heat developed by the LEDs48 (or 348) is transmitted through the printed circuit board 73 to thecentral portion 79 of the heat pipe 38. The heat is further transmittedto the side portions 83 a, 83 b and through the cover member 37 toambient surroundings.

As shown in the FIGS., in any of the embodiments disclosed herein, eachcoupling cavity 344 may extend fully through the body 340, although eachcoupling cavity 344 (or one or more coupling cavities) may extend onlypartially through the body 340. It should be noted that the LEDelement(s) 348 need not be located at an edge portion of the waveguidebody 340 (which embodiments are referred to as “edge lit”). Rather, oneor more of the coupling cavities 344 may be a blind cavity or throughbore of any suitable shape disposed at a location intermediate sidesurfaces and the end surface and an opposing end surface and the LEDelement(s) 48 may be disposed in the blind cavity or through bore toobtain an “interior lit” waveguide. In edge lit embodiments, the LEDelement(s) 48 may be above, below, and/or to the side of the edge andaligned therewith as shown and described in co-pending U.S. patentapplication Ser. No. 14/101,086, entitled “Optical Waveguides andLuminaires Incorporating Same,” filed Dec. 9, 2013 (Cree docket no.P2126US1). Further, it may be desirable to dispose one or more of theLED elements 48 at an angle α within the associated coupling. Forexample, where an LED element 48 extends into the waveguide body from anedge thereof, the central axis of the LED element 48 may be disposed ata non-zero angle with respect to the length, width, and/or thicknessdimensions of the waveguide body 40.

Also in any of the embodiments disclosed herein, a conical lightdiverter may be disposed in the blind cavity or through bore oppositethe LED element to direct light into the waveguide body 40, 340, ifdesired. For example, a light diverter as disclosed in U.S. patentapplication Ser. No. 13/839,949, filed Mar. 15, 2013, entitled “OpticalWaveguide and Lamp Including Same” (Cree docket No. P1961US1)incorporated by reference herein may be disposed in such a blind cavityor through bore.

The spacing, number, size, and geometry of extraction features 363determine the mixing and distribution of light in the waveguide body 340and light exiting therefrom. In the illustrated embodiment, theextraction features 363 comprise a series of ridges separated byintervening troughs at least some of which define one or more invertedV-shapes in cross section, as seen in the FIGS. Also, at least one (andperhaps more or all) of the extraction features 363 or any or all of theother extraction features disclosed herein may be continuous (i.e., itextends in a continuous manner), while any remaining extraction featuresmay comprise continuous or discontinuous ridges (i.e., partial linearand/or nonlinear features extending continuously or discontinuously)separated by intervening troughs. If desired, inflections or othersurface features may be provided in any of the extraction featuresdisclosed herein. Still further, for example, as seen in the illustratedembodiment, all of the extraction features 363 are symmetric withrespect to the centerline 352 of the body 340, although this need not bethe case. In addition to the foregoing, the waveguide body 340 and anyother waveguide body disclosed herein may be tapered in an overall sensefrom the coupling cavities 344 to the end surface in that there is lessmaterial at the general location of the end surface 95 than at portionsadjacent the coupling cavities 344. Such tapering may be effectuated byproviding extraction features that become deeper and/or more widelyseparated with distance from the coupling cavities 344. The taperingmaximizes the possibility that substantially all the light introducedinto the waveguide body 340 is extracted over a single pass of the lighttherethrough. This results in substantially all of the light strikingthe outward surfaces of the extraction features 363, which surfaces arecarefully controlled so that the extraction of light is also carefullycontrolled. The combination of tapering with the arrangement ofextraction features result in improved color mixing with minimumwaveguide thickness and excellent control over the emitted light.

It should be noted that there could be a different number of lightextraction features 363, as desired. In any event, the Lambertian orother distributions of light developed by the LED elements 348 areconverted into a distribution resulting in the illumination pattern 350.More specifically, the light developed by the LED element(s) 348 isemitted into center portions of the beam spread and to side portionspast imaginary planar surfaces normal to the bottom surface 343 andcoincident with side surfaces. As noted above, this lateral extent ofthe beam spread is substantially greater than a longitudinal extent ofthe beam spread of the light (i.e., the beam spread transverse to thelateral extent) of the illumination pattern 350. The illuminationpattern 350 can be modified through appropriate modification of thelight extraction elements. The brightness can be increased or decreasedby adding or omitting, respectively, LED elements 348.

As should be apparent from the foregoing, the reflective enclosuremember 39 is disposed above the waveguide body 340 opposite thesubstrate 343 a. The reflective enclosure member 39 includes a lowersurface 110 that is coated or otherwise formed with a white or specularmaterial. Further, one or more of the surfaces of the waveguide body maybe coated/covered with a white or specular material. Light that escapesthe upper surface 342 of the waveguide body 340 may be thus reflectedback into the waveguide body 340 so that light is efficiently extractedout the substrate 343 a. The lower surface 110 may have other than aplanar shape, such as a curved surface.

In all of the illustrated embodiments, the light emitted out thewaveguide body 340 is mixed such that point sources of light in the LEDelements 348 are not visible to a significant extent and the emittedlight is controlled and collimated to a high degree.

Referring next to FIGS. 18 and 19, a second embodiment of a luminaire210 that utilizes a waveguide is illustrated. The luminaire 210, as inthe previous embodiment disclosed herein, is particularly adapted foruse in general lighting applications, for example, as an outdoor roadway(including a driveway) or parking lot luminaire, or as any other indooror outdoor luminaire. The luminaire 210 includes a housing 212 adaptedto be mounted on a stanchion or pole 214 that may be similar oridentical to or different than the stanchion or pole 14. Moreparticularly, the housing 212 includes a mounting portion 216 that issized to accept an end of any of a number of differently-sizedconventional stanchions. The housing 212 is secured to the stanchion 214by a mounting assembly 217 comprising a clamping member 217 a (FIG. 30)and first and second fasteners 217 c, 217 d that extend through bores217 e, 217 f of the clamping member 217 a and into threaded bores 217 g,217 h (FIG. 18) extending into bosses (not shown) of the housing 212,thereby capturing the stanchion between the clamping member 217 and acurved seat member 217 k (best seen in FIG. 33) of the housing 212. Inaddition, an end 214 a of the stanchion 214 is disposed in any of anumber of seats defined by ridges and grooves in a pair of curvedmembers 219 a, 219 b carried by the housing so that the angle of thehousing 212 relative to the stanchion may be adjusted before thefasteners 217 c, 217 d are fully threaded into the threaded bores 217 g,217 h. Electrical connections (i.e., line, ground, and neutral) areeffectuated via a terminal block 218 disposed within a fittercompartment 220 of the mounting portion 216. The fitter compartment isaccessible via a movable fitter door 221, which is rotatable about apivoted hinge 222 and which can be maintained in a closed position by alatch 223. Wires (not shown) connect the terminal block to an LED drivercircuit in the housing to provide power thereto as noted in greaterdetail hereinafter.

Referring to FIGS. 18 and 19, the head portion 224 comprises a covermember 237, a heat exchanger 238, a reflective enclosure member 239, andan optical waveguide comprising, for example, a waveguide body or optic240. A gasket 241 is sandwiched between outer edges of the waveguidebody 240 and outer edges of the cover member 237. Fasteners in the formof screws 242 secure the outer edges of the waveguide body 240 and thegasket 241 to the outer edges of the cover member 237.

Referring next to FIGS. 20-25, the waveguide body 540 includes aplurality of light coupling cavities 544 a-544 i extending into thewaveguide body 540 from an end surface 576 thereof and a number of lightredirection elements 546. Light mixing features 580 are disposed on abottom surface 545 of the waveguide body 540. LED elements 596 (see FIG.25) are disposed in a stacked configuration within each of the pluralityof light coupling cavities 544 as described in greater detail below. Asin the previous embodiment, the waveguide body 540 may include a planarsubstrate, similar or identical to the substrate 343 a, if desired, orthe substrate may simply comprise the bottom surface 545 of thewaveguide body 540 as shown.

As seen in FIG. 21, the plurality of light coupling cavities includesthree groups 550 a-550 c, each of which includes three light couplingcavities of substantially the same shape. However, two of the couplingcavities of each group 550 a-550 c are larger than a remaining couplingcavity of the group and the remaining coupling cavity is disposedbetween the two larger coupling cavities. For example, group 550 a shownin FIG. 21 includes two larger coupling cavities 544 a, 544 c and aremaining coupling cavity 544 b. Similarly, group 550 b includes twolarger coupling cavities 544 e, 544 f and a remaining coupling cavity544 e, and group 550 c includes two larger coupling cavities 544 g, 544i and a remaining coupling cavity 544 h. Preferably, all of the lightcoupling cavities 544 a-544 i have the same shape, although other shapesmay be used to effectuate a desired illumination pattern.

Referring to FIG. 22, each light coupling cavity 544 includes twocoupling surfaces 552-1, 552-2 that are mirror images of one another oneither side of an axis 554 of symmetry. Planar portions 552-5, 552-6 ofthe respective coupling surfaces 552-1, 552-2 are spaced apart, andcurved portions 552-3, 552-4 of the respective coupling surfaces 552-1,552-2 meet along the axis of symmetry 554. Two control surfaces 556-1,556-2 are provided on each side of the coupling surfaces 552-1, 552-2adjacent one of the planar portions 552-5, 552-6 thereof and extend intothe waveguide 540 from the end surface 576. The coupling surfaces 552-1,552-2 and the control surfaces 556-1, 556-2 are shaped to direct lightemitted from an LED 548 substantially in defined paths in the waveguide.The coupling surfaces 556-1, 556-2 and the control surfaces 552-1, 552-2may be smooth, textured, curved, or otherwise shaped to affect lightmixing and/or redirection. In the embodiment shown in FIG. 22, each ofthe curved portions 552-3, 552-4 of the coupling surfaces 552-1, 552-2and the control surfaces 556-1, 556-2 has a piecewise linear shape. Eachof the curved portions 552-3, 552-4 preferably approximates a curve,while each of the control surfaces 556-1, 556-2 preferably approximatesa line.

The light redirection elements 546 include at least a plurality of lightextraction features 563 a-563 e. The light extraction features 563 a-563e are linear in overall side-to-side extent or shape and include fivewedge-shaped (in cross-section) extraction features. Further, the lightextraction features 563 a-563 e are preferably symmetric with respect toa centerline 552 of the waveguide body 540, although otherconfigurations are envisioned. In other embodiments, the width, length,and curvature and/or other shape(s) of the extraction features may varyas in the previous embodiments.

As shown in FIG. 25, LED elements 548 are disposed within or adjacentthe coupling cavities 544 a-544 i of the waveguide body 540. Each LEDelement 548 may be a single white or other color LED, or each maycomprise multiple LEDs either mounted separately or together on a singlesubstrate or package to form a module including, for example, at leastone phosphor-coated LED either alone or in combination with at least onecolor LED, such as a green LED, a yellow LED, a red LED, etc. In theembodiment of FIG. 25, individual blue-shifted yellow LEDs andindividual red LEDs are disposed in or adjacent the light couplingcavities. In general, at least one blue-shifted yellow LED is disposedin or adjacent each of the two larger coupling cavities of each group ofthree coupling cavities 550 and at least one red LED is disposed in oradjacent the remaining coupling cavity of each group. In the specificillustrated embodiment, each coupling cavity 544 receives five equallyspaced and stacked LEDs each disposed on a carrier 601 such that theLEDs are disposed in rows across a width of the waveguide 540. Thewaveguide body 540 therefore includes six sets of five stackedblue-shifted yellow LEDs in or adjacent the larger light couplingcavities and three sets of five stacked red LEDs disposed in or adjacentthe remaining light coupling cavities. The number and configuration ofLEDs 548 may vary depending on the shape of the coupling cavity.

The light developed by the LEDs 548 is directed into groups of lightrays by the control surfaces 552, wherein the rays of each group oflight rays are directed within a range of angles within the waveguidebody. Thus, beam control is accomplished by the coupling cavities. Suchlight travels through the waveguide body 540 and is redirecteddownwardly by the extraction features 563 as shown in FIG. 20 and isemitted out the second side of the waveguide body 540. As light isemitted from the second side, the light mixing features 580 promotecolor mixing in the event that different color LEDs 548 are used and/orpromote illuminance uniformity by the waveguide body 540 regardless ofwhether multi-color or monochromatic LEDs are used. The light mixingfeatures 580 have an elongate linear extent along a lateral direction559 of the waveguide body 540 and are rounded and convex incross-sectional shape.

The waveguide body 540, like the other embodiments disclosed herein,develops an illumination pattern 550 suitable for the uses describedherein as shown in FIG. 26. The waveguide body directs light developedby the LED element(s) toward a desired illumination target surface, suchas a roadway, with an illumination pattern. The illumination pattern 250is preferably, although not necessarily, offset with respect to a centerof the waveguide body as described above. The extraction features 563are configured to develop an asymmetric light distribution having alateral extent offset from the lateral axis 559 greater than alongitudinal extent aligned with the longitudinal axis 552.

Each LED element 548 receives power from a power supply of suitabletype, such as a SEPIC-type power converter 280 and/or other powerconversion circuits mounted by suitable fasteners 281 and location pins282 to an inner surface 283 of the cover member 237 above the reflectiveenclosure member 239. The power converter 280 and/or other powerconverter circuits receive power over wires that extend from theterminal block 218 through a wire tube 320 that extends through a wirecompartment 321 defined in part by a wiring cover 322. The wiring cover322 is maintained in place by a screw or other fastener that extendsinto a threaded boss 324 in the wire compartment 321. The wiring cover322 is further maintained in place by a shouldered member 328 forming apart of the cover member 237.

Referring to FIG. 18, the heat exchanger 238 includes a base plate 330that extends transversely relative to a plurality of heat dissipationplates 332. Ends 334 a, 334 b of the base plate 330 and a printedcircuit board (PCB) 335 are captured within inwardly-directed flanges336, 338 of the shouldered member 328 and a further shouldered member340 also forming a part of the cover member 237. The heat exchanger 238is seated against a T-shaped stop member 342. Apertures 344 in the covermember 237 and the fact that the heat exchanger 238 is open at thebottom thereof results in a path for convective air currents through theheat exchanger 238 to ambient surroundings, thereby facilitatingcooling.

The PCB 335 is fixedly maintained in position by the base plate 330 ofthe heat exchanger 238 against an end surface 340 of the reflectiveenclosure member 239 including side portions 340 a, 340 b and downwardlyextending spaced tab portions 340 c-340 j. Openings 341 a-341 i aredefined by the side portions and tab portions 340 a-340 j. The LEDs 248are mounted on the PCB 350 at locations coincident with the openings 341a-341 i. The cavities 244 a-244 i of the waveguide body 241 are alignedwith the openings 341 a-341 i, respectively, such that the LEDs 248 areadjacent or extend into the cavities 244 a-244 i.

As in the previous embodiment, and as seen in FIG. 18, the reflectiveenclosure member 239 is disposed above the waveguide body 240 oppositethe substrate 243 a. The reflective enclosure member 239 includes alower surface 310 that is coated or otherwise formed with a white orspecular material. Further, one or more of the surfaces of the waveguidebody may be coated/covered with a white or specular material. Light thatescapes the upper surface 236 of the waveguide body 240 may be thusreflected back into the waveguide body 240 so that light is efficientlyextracted out the substrate 243 a. The lower surface 310 may have otherthan a planar shape, such as a curved surface.

As noted above, any of the embodiments disclosed herein can be used inmany different applications, for example, a parking lot light, a roadwaylight, a light that produces a wall washing effect, a light usable in alarge structure, such as a warehouse, an arena, a downlight, etc. Aluminaire as disclosed herein is particularly adapted to develop highintensity light greater than 1000 lumens, and more particularly greaterthan 2000-5000 lumens, and can even be configured to develop 35,000 ormore lumens by adding LED elements and, possibly, other similar,identical or different waveguide bodies with associated LEDs in aluminaire.

The placement of multiple LED element(s) and the optics of the waveguidebodies overlay the illumination from each LED element onto each other,which further helps color mixing while maintaining a desired photometricdistribution. If necessary or desirable, color mixing may be enhanced byusing any of the structures or cavities disclosed in co-pendingapplications U.S. patent application Ser. No. 14/101,086, filed Dec. 9,2013, entitled “Optical Waveguides and Luminaires Incorporating Same,”(Cree docket no. P2126US1), U.S. patent application Ser. No. 14/101,132,filed Dec. 9, 2013, entitled “Waveguide Bodies Including RedirectionFeatures and Methods of Producing Same,” (Cree docket no. P2130US1),U.S. patent application Ser. No. 14/101,147, filed Dec. 9, 2013,entitled “Luminaire Using Waveguide Bodies and Optical Elements” (Creedocket no. P2131US1), and U.S. patent application Ser. No. 14/101,051,filed Dec. 9, 2013, entitled “Optical Waveguide and Lamp Including Same”(Cree docket no. P2151US1), owned by the assignee of the presentapplication and filed herewith, the disclosures of which areincorporated by reference herein.

If desired, any of the features disclosed in co-pending U.S. patentapplication Ser. No. 13/839,949 and/or U.S. patent application Ser. No.13/840,563 (Cree docket nos. P1961US1 and P2025US1, respectively), maybe used in the luminaire 40 as desired.

Further, any LED chip arrangement and/or orientation as disclosed inU.S. patent application Ser. No. 14/101,147, filed Dec. 9, 2013,entitled “Luminaire Using Waveguide Bodies and Optical Elements” (Creedocket no. P2131US1), incorporated by reference herein and owned by theassignee of the present application, may be used in the devicesdisclosed herein. Where two LED elements are used in each light couplingcavity (as in the illustrated embodiments), it may be desired toposition the LEDs elements within or adjacent the coupling cavity alonga common vertical axis or the LED elements may have different angularorientations, as desired. The orientation, arrangement, and position ofthe LEDs may be different or identical in each waveguide body section ofa waveguide as desired. Still further, each light coupling cavity may becylindrical or non-cylindrical and may have a substantially flat shape,a segmented shape, an inclined shape to direct light out a particularside of the waveguide body, etc.

The remaining FIGS. illustrate other embodiments. For example, FIGS.28-30 illustrate a further embodiment of a luminaire 800. FIGS. 31 and32 illustrate a heat sink 802 disposed adjacent an optic assembly 804.The optic assembly 804 includes a reflector element 806, a waveguide808, and a surround member 810. Referring to FIG. 33, electricalcomponents are disposed adjacent the reflector element 806 of the opticassembly 804. The electrical components 811 are further illustrated inFIGS. 44-46 and 50. FIGS. 47-49 illustrate the assembly of a driver 811a, the reflector element 239, and a waveguide 240 having a gasket 241disposed thereon, respectively, of the luminaire 800. FIGS. 34-39 and 42illustrate an additional embodiment of a luminaire 850. FIGS. 38, 39,and 41 also illustrate another embodiment of a luminaire 852, and FIG.41 illustrates a still further embodiment of a luminaire 854.

FIGS. 51-53 illustrate an embodiment that comprises a relatively smallluminaire 650 and FIGS. 54 and 55 show an embodiment that comprises arelatively large luminaire 652 that is otherwise similar in appearanceto the small luminaire 650 of FIGS. 51-53. Similarly, FIGS. 81-91illustrate an alternative embodiment of a luminaire 950 having arelative small size, and FIGS. 92-100 illustrate an alternativeembodiment of a luminaire 952 having a relatively large size. Theluminaires 650, 652, 900, 952 are adapted to be adjustably mounted on apole or stanchion in a fashion similar or identical to the previousembodiments, and are usable as roadway, parking lot, or as any otherindoor or outdoor luminaire luminaires.

Referring specifically to FIGS. 51-53 and FIGS. 81-91, the luminaire650, 950 includes a head portion 660, 960 including an upper covermember 662, 962, a lower door 664, 964 secured in any suitable fashionto the upper cover member 662, 962, and an optic assembly 666, 966retained in the upper cover member 662, 962.

Referring next to FIGS. 54 and 55, the luminaire 652, 952 includes ahead portion 670, 970 including an upper cover member 672, 972, a lowerdoor, and optic assembly (the latter two are not shown, but suchelements are similar or identical to the elements 664, 666 and 964, 966,except as to size) that are secured/retained in any suitable fashion tothe upper cover member 672, 972.

Referring next to FIGS. 56 and 82, the inner components of theembodiments 650, 652 and 950, 952 are identical, except as to the sizeof the optic assembly, and hence, only the inner components of theembodiment 650, 950 are described in detail herein. The optic assembly666, 966 includes an optical waveguide body 680, 980 made of thematerials specified hereinabove or any other suitable materials, asurround member 681, 981, and a reflective enclosure member 682, 982similar to the element 39 described above. A circuit compartment 684,984 with a cover 686, 986 is disposed atop the reflective enclosuremember 682, 982, and a power supply 688, 988 disposed in the circuitcompartment 684, 984 and that may be similar or identical to theSEPIC-type power converter 280 and/or other power conversion circuitsdescribed above. LED elements 690, 990 similar or identical to the LEDelements 348, 548 are disposed on a printed circuit board (PCB) 692, 992and extend into coupling cavities 694 (FIGS. 69-77), 994 (FIGS. 89-91)of the waveguide 680, 980, 980 a, 980 b, as in previous embodiments. Aheat sink 696, 996 is disposed behind the PCB 692, 992 to dissipate heatthrough vents that extend through the luminaire 650, 950 and terminateat upper and lower openings 400, 402. In addition, a terminal block 697,997 is mounted adjacent the heat sink 696, 996 and permits electricalinterconnection between the power supply 688, 988 and electrical supplyconductors (not shown).

The lower door 664, 964 includes stub shafts 404 (only one of which isvisible in FIGS. 59 and 82, respectively) which are disposed in bores406 in the upper cover member 662 (FIGS. 56, 58, and 59), 962 (FIG. 82)to allow the lower door 664, 964 to pivot. The door 664, 964 furtherincludes latch members 408 that, during assembly, engage and interferewith shouldered members 410 (see FIG. 60) to maintain the door 664, 964in a closed position as seen in FIGS. 60 and 83, respectively.

FIGS. 64-68, 80, 87-90, 94, and 95 illustrate the optic assembly 666,966, 1166 in greater detail. A process for fabricating the assembly 666,966, 1166 includes the steps of molding the waveguide body 680, 980, 983placing the reflective enclosure member 682, 982, 1182 onto thewaveguide body 680, 980, 983, and overmolding the surround member 681,981, 1181 onto the waveguide body 680, 980, 983 and/or the reflectivemember to maintain the reflective enclosure member, the waveguide body,and the surround member together in a unitary or integral fashion. Theoptic assembly 966 further includes an upper cover 982 a having curvedand/or tapered side surfaces to interfit with the housing 962. In eachluminaire 650, 950, 1150, the reflective enclosure members 682, 982,1182 has a size and shape (including tapered or curved side surfaces) toclosely receive the respective waveguide body 680, 980, 983 in a nestingfashion, as illustrated in FIG. 87. The unitary aspect of the opticassembly provides a seal around the waveguide body.

Any of the waveguide bodies disclosed herein may be used in theembodiments of FIGS. 51-55, 81-87, and 92 and 93, including thewaveguide bodies of FIGS. 61-77, 90, 91, and 96-99. For example, theluminaires 650, 652, 950, 952 may incorporate waveguide bodies 680 ofFIGS. 61-63 to achieve appropriate illumination distributions fordesired output light illumination levels. The waveguide bodies of FIGS.61-63 may be fabricated by a molding process that utilizes a toolingrecess common to production of all three waveguide bodies, and using aparticular bottom insert in the tooling cavity unique to each of thethree waveguide bodies. The insert allows for a central section of eachwaveguide body 680, 980, 980 a to have different extraction featuresand/or redirection features while a bottom surface 699 and an outboardportion 719 of an upper surface 720 are common to the waveguides 680,980, 980 a. For example, referring to FIG. 90, the dashed line 721outlines the central section of the waveguide body 980 formed using aparticular bottom insert in the tooling cavity. Similarly, a centralsection of each waveguide body 983, 983 a, 983 b may have differentextraction features and/or redirection features while a bottom surface1064 and an outboard portion 1066 of an upper surface 1068 are common tothe waveguide bodies 983, 983 a, 983 b. The different central sectionsof the waveguides allow for different illumination distribution patternsto be produced by the waveguide bodies. The varied illuminationdistribution patterns may be described in accordance with the AmericanInstitute of Architects lighting standards that are commonly known inthe art. The boundary of the illumination pattern on the illuminatedsurface is defined by the threshold of minimum acceptable lightingconditions, which depend on the roadway requirements, such as a highwayluminaire or parking lot luminaire. For example, the waveguide bodies680, 983 may provide an illumination pattern having a relatively shallowreach, for example, about one times the mounting height of theluminaire, in a y-direction extending away from the luminaire and a longrange distribution, for example, about seven times the mounting heightof the luminaire, in an x-direction extending to either side of theluminaire transverse to the y-direction. The spacing of the luminaireswould therefore be about one times the mounting height along they-direction and about seven times the mounting height along thex-direction. The waveguide bodies 980, 983 a may provide an illuminationpattern having a shallow reach, for example, about two times themounting height of the luminaire, in the y-direction and a medium rangedistribution, for example, about six times the mounting height of theluminaire, in the x-direction, such that the spacing of adjacentluminaires may be about two times the mounting height along they-direction and about six times the mounting height along thex-direction. Finally, the waveguide bodies 980 a, 983 b may produce anillumination pattern having a mid-range reach, for example, about threetimes the mounting height of the luminaire, in the y-direction whilehaving a medium range distribution, for example, about 4.7 times themounting height of the luminaire, in the x-direction, for a spacing ofadjacent luminaires of about three times the mounting height along they-direction and about 4.7 times the mounting height along thex-direction. The illumination patterns may be different from thedescriptions above depending on the number, spacing, colors, andorientation of the LEDs relative to the respective waveguide.

Further, the waveguide bodies 680, 980, 980 a may have a length alongthe y-direction ranging from about 75 mm to about 250 mm, preferablyfrom about 125 mm to about 175 mm, a width along the x-direction rangingfrom about 150 mm to about 300 mm, preferably from about 200 mm to about250 mm, and a height ranging from about 5 mm to about 50 mm, preferablyfrom about 15 mm to about 35 mm. The waveguide bodies 680, 980, 980 amay be used in a luminaire having a lumen output ranging from about2,000 lumens to about 12,000 lumens, and, more preferably, in luminaireshaving a lumen output between about 3,000 lumens to about 8,000 lumens.The waveguide bodies 983, 983 a, 983 b may have a length ranging fromabout 75 mm to about 300 mm, preferably from about 125 mm to about 200mm, a width ranging from about 350 mm to about 500 mm, preferably fromabout 400 mm to about 450 mm, and a height ranging from about 10 mm toabout 50 mm, preferably from about 20 mm to about 40 mm and may be usedin a luminaire having a lumen output ranging from about 10,000 lumens toabout 30,000 lumens and, more preferably, in luminaires having a lumenoutput between about 13,000 lumens and about 23,000 lumens.

FIG. 69 illustrates a bottom surface 699 common to the waveguide bodies680, 980, 980 a of FIGS. 61-77, 90, and 91. The bottom surface 699 istray-shaped and includes tapered side surfaces 700, 702, 704 disposedbetween an outer planar surface 706 and an inner planar base surface708. Referring also to FIGS. 75-75C, 76-76C, and 77-77C, the taperedside surfaces 700, 702, 704 are spaced from one another by intermediateplanar surfaces 710, 712. The surfaces 700, 702, 704, 710, 712circumscribe three sides 714 a-714 c of the waveguide body 680. A planartransverse side surface 716 (FIG. 77) bounds a fourth side 714 d of thewaveguide body 680 and extends between the surfaces 706 and 708. Firstand second light extraction ribs 715, 717 protrude away from the basesurface 708 and extend between the transverse surface 716 and portionsof the surfaces 700, 702, 704, 710, 712 opposite the transverse surface716. Each rib 715, 717 comprising a tapered inner surface 715 a, 717 a,and an outer surface 715 b, 717 b extracts light out of the waveguidebody 680.

The outboard portion 719 of the upper surface 720 of the waveguide body680 (FIGS. 61-77) generally includes first and second opposed sidesections 722, 724 adjacent the sides 714 a, 714 c, respectively. Acentral section 725 is disposed between the sides 714 b and 714 dintermediate the side sections 722, 724. The side sections 722, 724 arepreferably mirror images of one another (i.e., symmetric about a centerline 726), and hence, only the side section 722 will be described indetail. The side section 722 includes first, second, and thirdwedge-shaped members 730, 732, and 734. Each light extractionwedge-shaped member described herein may be linear in overallside-to-side extent or shape, and/or may have a linear, piece-wiselinear, and/or curved shape in cross-section. The innermost wedge-shapedmember 734 includes an outwardly-facing surface 736. The surface 736 mayhave light mixing features such as a scalloped and/or textured surface,as shown. The light mixing features to mix light from different lightsources. The waveguide bodies 980 and 980 a shown in FIGS. 90 and 91,respectively, have an outboard portion 1019 of an upper surface 1020similar to the outboard portion 719 of the upper surface 720 of thewaveguide body 680.

Referring to FIGS. 61-63 and 69-77, the central section 725 of thewaveguide body 680 extends between a tapered end portion 740 adjacentthe side 714 b and coupling cavities 742 that receive the lightdeveloped by the LED elements 690. The central section 725 includes apair of recessed wedge-shaped members 744, 746 transverse to thewedge-shaped members 730, 732, 734 (and the corresponding wedge-shapedmembers of the side section 724) and a rectangular planar surface 748that extends from the coupling cavities 742 to a tapered transitionsurface 750 adjacent the wedge-shaped member 746. The tapered transitionsurface 750 includes a scalloped surface 751. Redirection featurescomprising two pluralities of cavities 752, 754 extend into therectangular planar surface 748 and are symmetric about the center line726. Each cavity 752, 754 is generally prismatic in shape and the shapesand positions vary with distance from the coupling cavities 742. Eachcavity 752, 754 having a length thereof is disposed at an angle relativeto a lateral extent of the coupling cavities 742. The angle may rangebetween about 5 degrees and about 85 degrees, preferably between about15 degrees and about 45 degrees, and most preferably between about 25degrees and about 35 degrees. Four side surfaces of each cavity 752, 754taper together toward the bottom surface 699 of the waveguide body 680.In the illustrated embodiment as well as other embodiments describedherein, the waveguide body includes a plurality of redirection featuresand a plurality of extraction features, wherein the redirection featuresare relatively smaller than the extraction features. In some suchembodiments, at least one redirection feature has a linear extent in afirst direction and at least one extraction feature has a linear extentin a second direction different from the first direction.

Sample dimensions for the waveguide body 680 are provided in Table 1below in reference to FIGS. 75, 77, and 90B. Dimensions are in mm unlessotherwise noted. Each cavity 752, 754 may have a length ranging fromabout 0.5 mm to about 50 mm, preferably from about 1 mm to about 35 mm,and a width ranging from about 0.1 mm to about 10 mm, preferably fromabout 1 mm to about 5 mm.

TABLE 1 Waveguide body 680 FIG. 75 A 234.6 B 215.33 C 136.89 D 102.69 E108.65 F 10 G 12.82 H 2 I 10.16 FIG. 77 J 147.84 K 23.71 M 55 degreesFIG. 90B N 7 P 6.49 Q 4.92 R 0.079 S 6 T 7 U 7 V 3.54 W 16.0 degrees X18.5 degrees Y 22.0 degrees Z 27.5 degrees AA 34.5 degrees AB 44.0degrees AC 54.0 degrees AD 65.0 degrees AE 75.0 degrees AF 83.0 degreesAG 89.0 degrees AH 93.0 degrees AI 5 AJ 2.53 AL 16.0 degrees AK 18.5degrees AM 22.0 degrees AN 27.5 degrees AP 34.5 degrees AQ 44.0 degreesAR 54.0 degrees AS 65.0 degrees AT 75.0 degrees AU 83.0 degrees AV 89.0degrees AW 93.0 degrees

Referring to FIG. 90, the waveguide body 980 includes a central section1025 having a planar surface 1026 that extends from a plurality ofcoupling cavities 1028 to a transition surface 1030 adjacent the taperedend portion 1040 of the outboard portion 1019. At least a portion of thetransition surface 1030 may include light mixing features such as ascalloped and/or textured surface. A slotted cavity 1032 is formedadjacent the transition surface 1030 and has a v-shape about a centerline 1034. The planar surface 1026 includes two pluralities of lightredirection cavities 1036, 1038 similar to those of the waveguide bodyof FIG. 70. The cavities 1032, 1036, 1038 redirect light travelingthrough the waveguide body 980 laterally within the waveguide body 980.

FIG. 91 illustrates the waveguide body 980 a including a central section1042. Three wedge-shaped members 1044 extend across the central section1042 transverse to the wedge-shaped members of the side sections of theoutboard portion 1019. A transition surface 1046 having a scalloped edgeextends from a coupling portion 1048 to the adjacent wedge-shaped member1044. Two light redirection cavities 1050 are disposed along thecoupling portion 1048 opposite a plurality of coupling cavities 1052.Each cavity 1050 has an equilateral triangular shape and is disposedsuch that a side surface 1054 is parallel to a lateral extent of thecoupling portion 1048 and a point 1056 opposite the side surface 1054 isdisposed between the coupling cavities 1052 and the side surface 1054.The side surfaces of the cavities 1050 may include light mixing featuressuch as a scalloped and/or textured surface. Further, the cavities 1050extend from the coupling portion 1048 into the transition surface 1046.The cavities 1050 redirect light laterally within the waveguide towardtwo outer corners 1051 a, 1051 b opposite the coupling cavities 1052.

Referring next to FIGS. 90A and 90B, the plurality of light couplingcavities 1028 includes cavities 1028 a-1028 m that extend into thewaveguide body 980 from an end surface thereof. LED elements (see FIG.82) are disposed in a stacked configuration within each of the pluralityof light coupling cavities 1028 as described in greater detail below.The coupling cavities 742 of the waveguide body 680 have the same shapesand sizes of the coupling cavities 1028 of waveguide bodies 980, 980 a,and hence, the following description applies to all three waveguides680, 980, 980 a.

The plurality of light coupling cavities 1028 includes three groups 1060a-1060 d, each of which includes three light coupling cavities ofsubstantially the same shape. However, two of the coupling cavities ofeach group are larger than a remaining coupling cavity of the group andthe remaining coupling cavity is disposed between the two largercoupling cavities. For example, group 1060 a includes two largercoupling cavities 1028 a, 1028 c and a remaining coupling cavity 1028 b.Similarly, group 1060 b includes two larger coupling cavities 1028 d,1028 f and a remaining coupling cavity 1028 e, group 1060 c includes twolarger coupling cavities 1028 g, 1028 i and a remaining coupling cavity1028 h, and group 1060 d includes two larger coupling cavities 1028 j,1028 m and a remaining coupling cavity 1028 k. Preferably, all of thelight coupling cavities 1028 a-1028 m have the same shape, althoughother shapes may be used to effectuate a desired illumination pattern.

Each light coupling cavity 1028 includes two coupling surfaces 1062-1,1062-2 that are mirror images of one another on either side of an axis1064 of symmetry. The coupling surfaces 1062-1, 1062-2 of each largercoupling cavity are recessed slightly relative to the coupling surfaces1062-1, 1062-2 of the adjacent remaining smaller coupling cavity. Forexample, the coupling surfaces 1062 g-1, 1062 g-2 of the larger couplingcavity 1028 g are recessed slightly relative to the coupling surfaces1062 h-1, 1062 h-2 of the adjacent remaining coupling cavity 1028 h. Thecoupling surfaces 1062-1, 1062-2 are shaped to direct light emitted fromLEDs 990 substantially in defined paths in the waveguide. The couplingsurfaces 1062-1, 1062-2 may be smooth, textured, curved, or otherwiseshaped to affect light mixing and/or redirection. Each or some of thecurved portions 1062-1, 1062-2 may have a piecewise linear shape. In anembodiment illustrated in FIG. 90B, the angles for segments of thecurved portions 1062-1, 1062-2 of the waveguide body 980 having apiecewise linear shape are provided in Table 1. The coupling cavities ofthe waveguide bodies 680, 980, 980 a, 983, 983 a, and 983 b shown inFIGS. 71, 90, 91, 102, 103, and 104, respectively, have the same shapeas described above, although the sizes of the coupling cavities mayvary.

Similar to the waveguide bodies 680, 980, 980 a of FIGS. 71, 90, and 91,the waveguide bodies 983, 983 a, and 983 b of FIGS. 96-99 include abottom surface 1064 and an outboard portion 1066 of a top surface 1068are common to each waveguide. The bottom surface 1064 illustrated inFIG. 96 is tray-shaped, and includes planar side surfaces 1070 a-1070 ddisposed about an inner planar surface 1072. An outer planar surface1074 extends outwardly from and transverse to the side surfaces 1070a-1070 d. An inner recessed section 1076 includes two ridge-shaped lightextraction members 1078 spaced apart from one another and extendingparallel to side surfaces 1070 a, 1070 c. A rib 1080 protrudes from theinner recessed section 1076 along a center line 1082 of the waveguidebody 983.

Referring to FIG. 97, the outboard portion 1066 of the upper surface1068 includes first and second opposed side surfaces 1084, 1086 alongsides 1070 a, 1070 c, respectively. First and second side walls 1088 a,1088 b extend along a portion of the first and second side surfaces1084, 1086, respectively. Each side wall 1088 includes a planar surface1090 a, 1090 b formed by the respective side surfaces 1084, 1086 and arespective inner side surface 1092 a, 1092 b. The outboard portion 1066further includes an end portion 1096 having a wedge-shaped lightextraction member 1098 and a transition surface 1100. A coupling portion1102 along the side 1070 d includes a planar surface 1104 extendingbetween two pluralities of coupling cavities 1106 a, 1106 b that receivethe light developed by the LED elements. The coupling cavities 1106 a,1106 b are disposed adjacent to respective side walls 1088 a, 1088 bsuch that light incident on the side wall is totally internallyreflected within the waveguide bode 983, 983 a, 983 b. FIG. 100illustrates the total internal reflection of light on the side wall 1088along a side 1107 a while light escapes from a side 1107 b opposite theside 1107 a having no side wall feature. During use, first and secondgroups of light rays are reflected off of respective side walls 1088 a,1088 b and extracted through the respective members 1078 a, 1078 b ofthe bottom surface 1064 toward the center line 1082 such that the firstand second groups of light rays cross one another at the center line1082. Use of total internal reflection along the sides of the waveguidebodies 983, 983 a, 983 b allows for a reduction in size of the waveguidebody along the x-direction. Additionally, four protrusions 1108 a-1108 dextend outwardly from the coupling portion 1102 of the waveguide body983 along the side 1070 d. Two corners 1109 a, 1109 b of the waveguidebodies 983, 983 a, 983 b may have a rounded shape as shown in FIG. 95.In any embodiment, any sharp corner may be filleted and have a radius ofcurvature of less than 0.33 mm. Further, as seen in the presentembodiment, the linear extent of at least one extraction feature extendsthe entire length or width of the waveguide, and the linear extent of atleast one redirection feature is smaller than the linear extent of theextraction feature.

A central section 1110 is disposed between the side walls 1088 a, 1088 band extends between a coupling portion 1102 and the end portion 1096 ofthe outboard portion 1066. The central section 1110 includes two sidesections 1112 a, 1112 b that are preferably mirror images of one anotherand are symmetric about the center line 1082, and hence, only the sidesection will be described in detail. The side section 1112 a includes afirst plurality of wedge-shaped light extraction members 1114 and atransition area 1116 extending between the side wall 1088 a and a planarrectangular portion 1118. In the illustrated embodiment, the plurality1114 includes four wedge-shaped members and the transition area 1116 hasa scalloped surface. End surfaces of the plurality of wedge-shaped lightextraction members 1114 are spaced apart from the planar portion 1118 todefine a gap 1120 therebetween. A plurality of light redirectioncavities 1122 extending into the planar portion 1118 is disposed at anangle relative to a lateral extent of the adjacent coupling portion1102. The angle may range between about 5 degrees and about 85 degrees,preferably between about 15 degrees and about 45 degrees, and mostpreferably between about 25 degrees and about 35 degrees. Side surfacesof each cavity 1122 define a prismatic shape and taper together towardthe bottom surface 1064 of the waveguide body 983. A second plurality oflight extraction wedge-shaped members 1124 and a transition area 1126are disposed between the planar portion 1118 and the center line 1082,and extend between the coupling portion 1102 and the transition surface1100 of the end portion 1096. Additionally, the coupling cavities 1106a, 1106 b have the same shape relative to the coupling cavities 742,1028 described above, but differ in size. Referring to FIG. 97A, anglesfor segments of the curved portions of the coupling cavities 1106 a,1106 b having a piecewise linear shape are provided in Table 2.

Sample dimensions for the waveguide body 983 are provided in Table 2below in reference to FIGS. 97A, 97B, and 97C. Dimensions are providedin mm unless otherwise specified. Each cavity 1036, 1038 may have alength ranging from about 0.1 mm to about 50 mm, preferably from about 1mm to about 35 mm, and a width ranging from about 0.1 mm to about 10 mm,preferably from about 0.1 mm to about 5 mm.

TABLE 2 Waveguide body 983 FIG. 97A BB 421.78 BC 363 BD 134.77 BE 165.07BF 16.0 degrees BG 18.5 degrees BH 22.0 degrees BJ 27.5 degrees BK 34.5degrees BM 44.0 degrees BN 54.0 degrees BP 65.0 degrees BQ 75.0 degreesBR 83.0 degrees BS 89.0 degrees BT 93.0 degrees FIG. 97B BU 3 BV 15 BW3.02 BX 60 degrees FIG. 97C BY 3 BZ 60 degrees CA 55 degrees CB 55degrees CC 15 CD 29.1

The waveguide body 983 a of FIG. 98 includes a central section 1128similar to the central section of the waveguide body of FIG. 12 exceptfor the following differences. The first plurality of wedge-shaped lightextraction members 1114 includes three wedge-shaped members and thetransition area 1116 is smooth. Further, the plurality of lightredirection cavities 122 includes a different number, sizes, and shapesthereof.

As with the previous embodiments, the central section 1130 of thewaveguide body 983 b of FIG. 99 includes two side sections 1132 a, 1132b that are preferably mirror images of one another. Each side section1132 includes first and second pluralities of wedge-shaped members 1134,1136 that are disposed transverse to one another. Two wedge-shaped lightextraction members of the first plurality 1134 and a transition surface1138 extend between the side wall 1088 a and the second plurality ofwedge-shaped members 1136. Two wedge-shaped light redirection members ofthe second plurality 1136 and a transition surface 1140 are disposedbetween the first plurality 1134 and the center line 1082. The secondplurality 1136 and transition surface 1140 extend between the couplingportion 1102 and the transition surface 1100 of the end portion 1096. Afirst plurality of light redirection cavities 1142 is disposed at anangle relative to a lateral extent of the coupling portion 1102 and isaligned across the first and second pluralities of wedge-shaped members1134, 1136. A second plurality of light redirection cavities 1144extends from the coupling portion 1102 into the transition surface 1138of the first plurality of wedge-shaped members 1134. Each cavity 1144has an equilateral triangular shape and is disposed such that a sidesurface 1146 is parallel to the side 1070 d and a point 1148 oppositethe side surface 1146 is disposed between the coupling cavities 1106 aand the side surface 1146. The cavities 1144 redirect light laterallywithin the waveguide 983 b toward two outer corners 1149 a, 1149 bopposite the coupling cavities 1106 a, 1106 b.

In some embodiments, the waveguide body includes a plurality ofredirection features and a plurality of extraction features, wherein theredirection features are relatively smaller than the extractionfeatures. In other embodiments, at least one redirection feature has alinear extent in a first direction and at least one extraction featurehas a linear extent in a second direction different from the firstdirection. In further embodiments, the linear extent of at least oneextraction feature extends the entire length or width of the waveguide,and the linear extent of the at least one redirection feature is smallerthan the linear extent of the extraction feature. In still furtherembodiments, extraction features are disposed on a bottom surface of thewaveguide and redirection features extend into an upper surface of thewaveguide opposite the bottom surface. In other embodiments, theredirection features are disposed at an angle relative to a lateralextent of a plurality of coupling cavities and the extraction featuresare disposed perpendicular and/or parallel to the lateral extent of theplurality of coupling cavities. Still further, the waveguide dimensionsare exemplary only, it being understood that one or more dimensionscould be varied. For example, the dimensions can all be scaled togetheror separately to arrive at a larger or smaller waveguide body, ifdesired.

While a uniform distribution of light may be desired in certainembodiments, other distributions of light may be contemplated andobtained using different arrays of extraction features.

Other embodiments of the disclosure including all of the possibledifferent and various combinations of the individual features of each ofthe foregoing embodiments and examples are specifically included herein.Thus, for example, a luminaire incorporating a waveguide of one of thedisclosed shapes may include extraction features of the same or adifferent shape, and the extraction features may be symmetric orasymmetric, the luminaire may have combinations of features from each ofthe disclosed embodiments, etc. without departing from the scope of theinvention.

Further, any of the embodiments disclosed herein may include a powercircuit having a buck regulator, a boost regulator, a buck-boostregulator, a SEPIC power supply, or the like, and may comprise a drivercircuit as disclosed in U.S. patent application Ser. No. 14/291,829,filed May 30, 2014, entitled “High Efficiency Driver Circuit with FastResponse” by Hu et al. (Cree docket no. P2276US1, attorney docket no.034643-000618) or U.S. patent application Ser. No. 14/292,001, filed May30, 2014, entitled “SEPIC Driver Circuit with Low Input Current Ripple”by Hu et al. (Cree docket no. P2291US1, attorney docket no.034643-000616) incorporated by reference herein. The circuit may furtherbe used with light control circuitry that controls color temperature ofany of the embodiments disclosed herein in accordance with user inputsuch as disclosed in U.S. patent application Ser. No. 14/292,286, filedMay 30, 2014, entitled “Lighting Fixture Providing Variable CCT” by Popeet al. (Cree docket no. P2301US1) incorporated by reference herein.

Any of the embodiments disclosed herein may include one or morecommunication components forming a part of the light control circuitry,such as an RF antenna that senses RF energy. The communicationcomponents may be included, for example, to allow the luminaire tocommunicate with other luminaires and/or with an external wirelesscontroller, such as disclosed in U.S. patent application Ser. No.13/782,040, filed Mar. 1, 2013, entitled “Lighting Fixture forDistributed Control” or U.S. provisional application No. 61/932,058,filed Jan. 27, 2014, entitled “Enhanced Network Lighting” both owned bythe assignee of the present application and the disclosures of which areincorporated by reference herein. More generally, the control circuitryincludes at least one of a network component, an RF component, a controlcomponent, and a sensor. The sensor, such as a knob-shaped sensor, mayprovide an indication of ambient lighting levels thereto and/oroccupancy within the room or illuminated area. Such sensor may beintegrated into the light control circuitry.

INDUSTRIAL APPLICABILITY

When one uses a relatively small light source which emits into a broad(e.g., Lambertian) angular distribution (common for LED-based lightsources), the conservation of etendue, as generally understood in theart, requires an optical system having a large emission area to achievean asymmetric angular light distribution. In the case of parabolicreflectors, a large optic is thus generally required to achieve highlevels of collimation. In order to achieve a large emission area in amore compact design, the prior art has relied on the use of Fresnellenses, which utilize refractive optical surfaces to direct andcollimate the light. Fresnel lenses, however, are generally planar innature, and are therefore not well suited to re-directing high-anglelight emitted by the source, leading to a loss in optical efficiency. Incontrast, in the present invention, light is coupled into the optic,where primarily TIR is used for re-direction and light distribution.This coupling allows the full range of angular emission from the source,including high-angle light, to be re-directed, resulting in higheroptical efficiency in a more compact form factor.

While specific coupling features and extraction feature parametersincluding shapes, sizes, locations, orientations relative to a lightsource, materials, etc. are disclosed as embodiments herein, the presentinvention is not limited to the disclosed embodiments, inasmuch asvarious combinations and all permutations of such parameters are alsospecifically contemplated herein. Any of the features such as variousshaped coupling cavities, LED elements, redirection features, extractionfeatures, etc. described and/or claimed in U.S. patent application Ser.No. 13/842,521, (Cree docket no. P1946US1), U.S. patent application Ser.No. 13/839,949, (Cree docket no. P1961US1), U.S. patent application Ser.No. 13/841,074, filed Mar. 15, 2013, entitled “Optical Waveguide Body”(Cree docket no. P1968US1), U.S. patent application Ser. No. 13/840,563,(Cree docket no. P2025US1), U.S. patent application Ser. No. 14/101,086,filed Dec. 9, 2013, entitled “Optical Waveguides and LuminairesIncorporating Same”, (Cree docket no. P2126US1), U.S. patent applicationSer. No. 14/101,132, filed Dec. 9, 2013, entitled “Waveguide BodiesIncluding Redirection Features and Methods of Producing Same,” (Creedocket no. P2130US1), U.S. patent application Ser. No. 14/101,147, filedDec. 9, 2013, entitled “Luminaire Using Waveguide Bodies and OpticalElements” (Cree docket no. P2131US1), U.S. patent application Ser. No.14/101,129, filed Dec. 9, 2013, entitled “Simplified Low Profile Modulewith Light Guide for Pendant, Surface Mount, Wall Mount and Stand AloneLuminaires” (Cree docket no. P2141US1), and U.S. patent application Ser.No. 14/101,051, filed Dec. 9, 2013, entitled “Optical Waveguide and LampIncluding Same” (Cree docket no. P2151US1), International ApplicationNo. PCT/US14/13931, filed Jan. 30, 2014, entitled “Optical Waveguidesand Luminaires Incorporating Same” (Cree docket No. P2126WO), andInternational Application No. PCT/U.S. Ser. No. 14/030,017, filed Mar.15, 2014, entitled “Optical Waveguide Body” (Cree docket No. P2225WO)incorporated by reference herein and owned by the assignee of thepresent application may be used in a luminaire, either alone or incombination with one or more additional elements, or in varyingcombination(s) to obtain light mixing and/or a desired light outputdistribution. Thus, for example, any of the luminaires disclosed hereindisclosed herein may include one or more waveguide bodies includingcoupling features, one or more light redirection features, one or moreextraction features or optics, and/or particular waveguide body shapesand/or configurations as disclosed in such applications, as necessary ordesirable. Other waveguide body form factors and luminairesincorporating such waveguide bodies are also contemplated.

At least some of the luminaires disclosed herein are particularlyadapted for use in installations, such as outdoor products (e.g.,streetlights, high-bay lights, canopy lights) preferably requiring atotal luminaire output of at least about 2,000 lumens or greater, and,in some embodiments, a total luminaire output of up to about 10,000lumens, and, in other embodiments, a total lumen output from about10,000 lumens to about 23,000 lumens. Further, the luminaires disclosedherein preferably develop a color temperature of between about 2500degrees Kelvin and about 6200 degrees Kelvin, and more preferablybetween about 3000 degrees Kelvin and about 6000 degrees Kelvin, and, insome embodiments, between about 3,500 degrees Kelvin and about 4,500degrees Kelvin. Also, at least some of the luminaires disclosed hereinpreferably exhibit an efficacy of at least about 90 lumens per watt, andmore preferably at least about 100 lumens per watt, and more preferably,about 110 lumens per watt. Further, at least some of the waveguidebodies used in the luminaires disclosed herein preferably exhibit anoverall efficiency (i.e., light extracted out of the waveguide bodydivided by light injected into the waveguide body) of at least about 90percent. A color rendition index (CRI) of at least about 80 ispreferably attained by at least some of the luminaires disclosed herein,with a CRI of at least about 85 being more preferable. The luminairesdisclosed herein produce a scotopic to photopic (S/P) ratio of at least1.4, preferably at least 2.0. Any desired form factor and particularoutput light distribution, including up and down light distributions orup only or down only distributions, etc. may be achieved.

Embodiments disclosed herein are capable of complying with improvedoperational standards as compared to the prior art as follows:

State of the art Improved standards standards achievable by presentembodiments Input coupling 90% About 95% plus improvements efficiencythrough color mixing, source mixing, (coupling + and control within thewaveguide body) waveguide body Output efficiency 90% About 95%: improvedthrough (extraction) extraction efficiency plus controlled distributionof light from the waveguide body Total system ~80% About 90%: greatcontrol, many choices of output distribution

In certain embodiments, the waveguide bodies used in the luminairesdisclosed herein may generally taper from a central portion to anoutside edge thereof so that substantially all light is extracted duringa single pass of each light ray from the LED element(s) to the outeredge of the waveguide body. This extraction strategy maximizes theincidence of light rays impinging on an outer side of each extractionfeature and being reflected out a surface (or surfaces) of the waveguidebody in a controlled manner, as opposed to striking other surfaces at anangle greater than the critical angle and escaping as uncontrolledlight. The outer sides of the extraction features are accurately formedso that control is maintained over the direction of extracted light,thereby allowing a high degree of collimation. Still further, thewaveguide body is very low profile, leaving more room for heat exchangerstructures, driver components, and the like in the luminaire. Also,glare is reduced as compared with other lamps using LED light sourcesbecause light is directed outwardly in the waveguide body while beingextracted from the waveguide body by the extraction features such thatthe resulting emitted light is substantially mixed and substantiallyuniformly distributed throughout the beam angle. The result is a lightdistribution that is pleasing and particularly useful for generalillumination and other purposes using a light source, such as one ormore LED element(s).

In some embodiments, one may wish to control the light rays such that atleast some of the rays are collimated, but in the same or otherembodiments, one may also wish to control other or all of the light raysto increase the angular dispersion thereof so that such light is notcollimated. In some embodiments, one might wish to collimate to narrowranges, while in other cases, one might wish to undertake the opposite.Any of these conditions may be satisfied by the luminaires utilizingwaveguide bodies disclosed herein through appropriate modificationthereof.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The use of the terms “a” and “an” and “the” and similar references inthe context of describing the invention (especially in the context ofthe following claims) are to be construed to cover both the singular andthe plural, unless otherwise indicated herein or clearly contradicted bycontext. Recitation of ranges of values herein are merely intended toserve as a shorthand method of referring individually to each separatevalue falling within the range, unless otherwise indicated herein, andeach separate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g., “such as”) provided herein, isintended merely to better illuminate the disclosure and does not pose alimitation on the scope of the disclosure unless otherwise claimed. Nolanguage in the specification should be construed as indicating anynon-claimed element as essential to the practice of the disclosure.

Numerous modifications to the present disclosure will be apparent tothose skilled in the art in view of the foregoing description. Preferredembodiments of this disclosure are described herein, including the bestmode known to the inventors for carrying out the disclosure. It shouldbe understood that the illustrated embodiments are exemplary only, andshould not be taken as limiting the scope of the disclosure.

We claim:
 1. A luminaire, comprising: a housing; an optical waveguidedisposed in the housing comprising a plurality of light couplingcavities; a plurality of LEDs disposed in the housing adjacent theplurality of coupling cavities; and a mounting apparatus adapted tomount the luminaire on a roadway stanchion.
 2. The luminaire of claim 1,in combination with a roadway stanchion on which the housing is mounted.3. The luminaire of claim 1, wherein the plurality of LEDs comprisesphosphor-converted LEDs.
 4. The luminaire of claim 1, wherein theplurality of LEDs includes phosphor-converted LEDs and red LEDs.
 5. Theluminaire of claim 4, wherein the first plurality of light couplingcavities includes third and fourth pluralities of cavities and whereinblue shifted yellow LEDs are disposed in the third plurality of cavitiesand red LEDs are disposed in the fourth plurality of cavities.
 6. Theluminaire of claim 5, wherein multiple blue shifted yellow LEDs aredisposed in each of the third plurality of cavities and multiple redLEDs are disposed in each of the fourth plurality of cavities.
 7. Theluminaire of claim 1, wherein the optical waveguide includes an emissionsurface and light mixing features on a surface opposite the emissionsurface.
 8. The luminaire of claim 7, wherein the optical waveguideincludes extraction features disposed between the light couplingcavities and the emission surface.
 9. The luminaire of claim 8, whereinat least one of the extraction features has a linear extent.
 10. Theluminaire of claim 1, further including a heat transfer member thermallycoupled to the plurality of LEDs.
 11. The luminaire of claim 1, whereineach coupling cavity is adapted to receive light developed by multipleLEDs, and wherein at least two of the LEDs have different spectralemission characteristics.
 12. An optical waveguide body of opticallytransmissive material that exhibits a total internal reflectancecharacteristic, comprising: an array of light coupling features; atleast one light redirection surface offset with respect to the array oflight coupling features and extending along a first direction; and atleast one extraction surface extending along a second directiontransverse to the first direction.
 13. The optical waveguide body ofclaim 12, wherein the body further includes at least one side surfacefor redirecting light in the body toward the at least one lightredirection feature.
 14. The optical waveguide body of claim 12, whereinthe at least one light redirection surface defines a cavity extendinginto the body from a first side thereof.
 15. The optical waveguide bodyof claim 14, wherein the at least one light extraction surface isdisposed at a first side of the body.
 16. The optical waveguide body ofclaim 15, further including an additional light extraction featuredisposed at a second side of the body opposite the first side.
 17. Theoptical waveguide body of claim 16, wherein the additional lightextraction features is ridge-shaped.
 18. The optical waveguide body ofclaim 12, further including at least one cavity proximate the array oflight coupling features configured to redirect light traveling throughthe waveguide body laterally within the waveguide body.
 19. The opticalwaveguide body of claim 12, further including an additional array oflight coupling features, at least one additional light redirectionsurface offset with respect to the additional array of light couplingfeatures and extending along a first direction, and at least oneadditional extraction surface extending along a second directiontransverse to the first direction.
 20. The optical waveguide body ofclaim 19, wherein the body further includes at least one additional sidesurface for redirecting light in the body toward the at least oneadditional light redirection feature.
 21. The optical waveguide body ofclaim 20, wherein the light redirection features are disposed betweenthe light extraction features.
 22. An optical waveguide body ofoptically transmissive material that exhibits a total internalreflectance characteristic, comprising: a coupling portion for receivinglight, a transmission portion for transmitting light through at least aportion of the body and an extraction portion for extracting light outof the body; wherein the transmission portion includes light redirectionfeatures extending along a first direction and the extraction portionincludes extraction features extending along a second directiontransverse to the first direction.
 23. The optical waveguide body ofclaim 22, wherein the body further includes first and second opposedside surfaces for redirecting light in the body toward the lightredirection features.
 24. The optical waveguide body of claim 23,wherein each light redirection feature comprises a cavity extending intothe body from a first side thereof.
 25. The optical waveguide body ofclaim 22, further including additional light extraction features,wherein each light extraction feature is disposed at a first side of thebody and the additional light extraction features are disposed at asecond side of the body opposite the first side.
 26. The opticalwaveguide body of claim 25, wherein the additional light extractionfeatures are ridge-shaped.
 27. The optical waveguide body of claim 22,wherein the body further includes light mixing features for mixing lightfrom different light sources.
 28. The optical waveguide body of claim22, wherein the light redirection features include at least one cavityproximate the coupling portion configured to redirect light travelingthrough the waveguide body laterally within the waveguide body.
 29. Theoptical waveguide body of claim 22, wherein the coupling portioncomprises first and second spaced light coupling sections.
 30. Theoptical waveguide body of claim 29 wherein the light redirectionfeatures are disposed between the light coupling portion and the lightextraction features.
 31. An optical assembly, comprising: an opticalwaveguide; an enclosure having a recess that receives the opticalwaveguide; and a surround member formed about the housing and thewaveguide for securing the optical waveguide in the recess.
 32. Theoptical assembly of claim 31, wherein the surround member is molded toat least to one of the enclosure and the optical waveguide.
 33. Theoptical assembly of claim 31, wherein the surround member is molded toboth the enclosure and the optical waveguide.